Card printing mechanism with card return path

ABSTRACT

Card processing mechanisms and methods whereby after a card has been processed on one surface thereof at a card processing station such as, but not limited to, a card printing mechanism, the card can be recirculated back upstream of the card processing station along a return card travel path that is separate from the primary card travel path through the card processing station where the card can then be reintroduced back into the primary card travel path and transported through the card processing station a second time. As the card is being returned along the return card travel path, the card can be flipped over so that when the card is transported back through the card processing station, the opposite surface of the card can be processed.

FIELD

This disclosure relates to card processing systems that personalize orotherwise process plastic cards such as financial cards including creditand debit cards, identification cards, driver's licenses, gift cards,and other plastic cards.

BACKGROUND

Plastic cards such as financial cards including credit and debit cards,identification cards, driver's licenses, gift cards, and other plasticcards may be personalized with personal information of the intended cardholder. Examples of personalization include, but not are limited to,names, addresses, photographs, account numbers, employee numbers, or thelike. The personal information may be applied to the card in a number ofdifferent ways including, but not limited to, printing on a surface ofthe document, storing the information on a magnetic stripe disposed onthe card, and storing the information on an integrated circuit chip orsmart chip embedded in the card.

Card processing systems that personalize plastic cards are utilized byinstitutions that issue such personalized plastic cards. In some cases,card processing systems can be designed for relatively small scale,individual card personalization in relatively small volumes, for examplemeasured in tens or low hundreds per hour. In these mechanisms, a singledocument to be personalized is input into a card processing system,which typically includes one or two processing capabilities, such asprinting and laminating. These processing machines are often termeddesktop processing machines because they have a relatively smallfootprint intended to permit the processing machine to reside on adesktop. Many examples of desktop processing machines are known, such asthe SD or CD family of desktop card printers available from EntrustDatacard Corporation of Shakopee, Minn. Other examples of desktopprocessing machines are disclosed in U.S. Pat. Nos. 7,434,728 and7,398,972, each of which is incorporated herein by reference in itsentirety.

For large volume batch production of personalized cards (for example, onthe order of high hundreds or thousands per hour), institutions oftenutilize card processing systems that employ multiple processing stationsor modules to process multiple cards at the same time to reduce theoverall per card processing time. Examples of such machines include theMX and MPR family of central issuance processing machines available fromEntrust Datacard Corporation of Shakopee, Minn. Other examples ofcentral issuance processing machines are disclosed in U.S. Pat. Nos.4,825,054, 5,266,781, 6,783,067, and 6,902,107, all of which areincorporated herein by reference in their entirety.

SUMMARY

Card processing mechanisms, systems and methods are described wherebyafter a card has been processed on one surface thereof at a cardprocessing station such as, but not limited to, a card printingmechanism, the card can be recirculated back upstream of the cardprocessing station along a return card travel path that is separate fromthe primary card travel path through the card processing station wherethe card can then be reintroduced back into the primary card travel pathand transported through the card processing station a second time. Asthe card is being returned along the return card travel path, the cardcan be flipped over so that when the card is transported back throughthe card processing station, the opposite surface of the card can beprocessed.

Processing as used herein is intended to encompass any processingoperation on a card surface including, but not limited to, printing,laminating, indenting, embossing, and other processing operations. Inone embodiment, the card processing station is configured to perform aprinting operation. Printing can include drop-on-demand printing with anultra-violet (UV) curable ink, printing using a thermal dye transferribbon, laser marking using a laser, retransfer printing, and other cardprinting techniques.

In some embodiments, improved card processing systems include a cardprinting mechanism having a primary card path and a separate return cardpath. The return card path allows a card that has been fed through aprint station to be returned back to the primary card path at a portionupstream of the print station so that the card can be fed again throughthe print station. One or more card reorienting mechanisms (e.g.,flippers) can be located on the return card path to orient the card intoa desired position for the second pass through the print station. Insome embodiments, the card reorienting mechanism positions the card sothat the same surface of the card that was processed during the firstpass through the print station can be processed during the second passthrough the print station. In other embodiments, the card reorientingmechanism can position the card so that the opposite side of the cardcan be processed during the second pass through the print station. Thecard return path can have any general shape as long as it functions toefficiently return cards to the print station for a second pass throughthe print station. In some embodiments, the return card path can be onsubstantially the same plane as the primary card path. Alternatively,the return card path can be located on a plane that is above or belowthe plane of the primary card path. In systems that employ a module orcomponent upstream and/or downstream of the card printing mechanism thathas a lower maximum card processing rate, the use of a return card pathallows the card printing mechanism to process cards at a higher rate andcan eliminate the need for a second card printing mechanism, whichreduces the cost and footprint of the system.

In one embodiment, a method of processing cards in a card processingsystem that includes a card printing mechanism with a print stationincludes printing on a first side of a first card in the card processingsystem using the print station of the card printing mechanism. Afterprinting on the first side of the first card, a second side of a secondcard within the card processing system is printed on using the printstation, where the second card includes printing on a first side thereofthat was previously applied to the first side thereof using the printstation. In addition, after printing on the second side of the secondcard, printing on a second side of the first card is performed using theprint station. In another embodiment, after printing on the first sideof the first card and before printing on the second side of the firstcard, a first side or a second side of a plurality of cards in additionto the second card can be printed on using the print station.

In one embodiment, the card processing station with the return cardtravel path can process cards at a card rate that is higher, for exampleup to twice as high, than a card processing rate of card processingstations immediately upstream and/or downstream of the card processingstation.

In another embodiment, the card processing system can be configured suchthat a card can travel through the card processing system in a firstorientation, for example vertical relative to the ground. However, uponreaching a card processing station, for example the card processingstation with the return card travel path, the card can be rotated 90degrees to a second orientation, for example horizontal relative to theground, for processing within the card processing station. Afterprocessing in the card processing station is finished, the card can berotated back to the first orientation if necessary for furtherprocessing downstream of the card processing station.

The card processing mechanisms and methods described herein can be usedin large volume, batch production or central issuance card processingsystems as well as lower volume, desktop card processing systems.

DRAWINGS

FIG. 1 schematically illustrates an embodiment of a card processingsystem that can utilize the card printing mechanism described herein.

FIG. 2 illustrates an example of a sequence of cards progressing throughthe card printing mechanism described herein.

FIG. 3 illustrates a sequence similar to FIG. 2 but with the cardsadvanced one position.

FIG. 4 illustrates a sequence similar to FIG. 3 but with the cardsadvanced another position.

FIG. 5 is a perspective view of a portion of an example card printingmechanism showing mechanisms for rotating the cards from one orientationto another.

DETAILED DESCRIPTION

FIG. 1 illustrates an embodiment of a card processing system 10 that isconfigured to personalize and otherwise process plastic cards such asfinancial cards including credit and debit cards, identification cards,driver's licenses, gift cards, and other plastic cards. The personalinformation may also be referred to as variable data since the datavaries from card to card. Examples of personal information include, butnot are limited to, names, addresses, photographs, account numbers,employee numbers, or the like. Non-personal, or non-variable, data suchas corporate logos, printed backgrounds, and the like may also beapplied to the cards. The personal and non-personal information may beapplied to a card in the system 10 in a number of different waysincluding, but not limited to, printing on a surface of the card,storing the information on a magnetic stripe disposed on the card, andstoring the information on an integrated circuit chip or smart chipembedded in the card.

In the example illustrated in FIG. 1, the system 10 can include a cardfeed mechanism 12, a card processing mechanism 14, a card printingmechanism 16 that can also be referred to as a card processingmechanism, another card processing mechanism 18, and a card output 20into which processed cards are output. The card processing system 10illustrated in FIG. 1 is a large volume, batch production or centralissuance card processing system. However, the card printing mechanism 16described herein can be used in other card processing systems includingin lower volume, desktop card processing systems.

The mechanisms 14, 16, 18 can be arranged in any order in the system 10.In addition, not all of the mechanisms 14, 16, 18 need to be utilized.For example, in one embodiment, the mechanism 16 can be used by itselfwithout the other mechanisms 14, 18. In addition, additional cardprocessing mechanisms can be utilized with the mechanisms 14, 16, 18.

The card feed mechanism 12 feeds cards to be processed by the system 10onto a card processing path 22 at up to a first card rate. The card rateof the feed mechanism 12 refers to how fast the mechanism 12 can feedcards one by one into the processing path 22. In one embodiment, thefirst card rate can be up to about 3000 cards per hour. The card feedmechanism 12 can include one or more card hoppers containing cardswaiting to be fed one-by-one onto the card processing path 22.

The card processing mechanism 16 is disposed on and along the cardprocessing path 22 to receive cards. The card processing mechanism 16 isconfigured to perform a processing operation on each card. In oneembodiment, the card processing mechanism 16 is configured to performprinting. Examples of printing include drop-on-demand printing with a UVcurable ink, printing using a thermal dye transfer ribbon, retransferprinting, laser marking using a laser, and other card printingtechniques.

As discussed in further detail below with respect to FIGS. 2-4, when thecard processing mechanism 16 is configured to perform printing, theprocessing mechanism 16 can be referred to as a card printing mechanismthat has a primary card travel path 24 that is collinear with the cardprocessing path 22, at least one print station 26 on the primary cardtravel path 24 that performs a printing operation on a surface of a cardon the primary card travel path 24, and a return card travel path 28that returns a card to a location on the primary card travel path 24that is upstream of the at least one print station 26 after the card hasbeen printed on by the at least one print station 26. When configured asa card printing mechanism, the card processing mechanism 16 can processcards at up to a card rate that is greater than the first card rate. Forexample, the mechanism 16 can have a second card rate of up to about6000 cards per hour or more. The card rate of the card processingmechanism 16 refers to how fast (i.e. the rate) the card processingmechanism 16 can perform its intended processing operation(s) on thecards.

Returning to FIG. 1, in the illustrated example, the card processingmechanism 14 is disposed on and along the card processing path 22downstream of the card feed mechanism 12. The card processing mechanism14 is configured to perform one or more processing operations on eachcard at up to the first card rate, for example up to about 3000 cardsper hour. The card rate of the card processing mechanism 14 refers tohow fast (i.e. the rate) the card processing mechanism 14 can performits intended processing operation(s) on the cards. The card processingmechanism 14 can be a smart card programming mechanism that isconfigured to, for example, program a chip embedded in each card. Thesmart card programming mechanism can be configured to program one cardat a time. Alternatively, the smart card programming mechanism can beconfigured to simultaneously program multiple cards. Example of a smartcard programming mechanisms that simultaneously program multiple cardsthat could be utilized are described in U.S. Pat. No. 6,695,205(disclosing an elevator-type smart card programming mechanism) and U.S.Pat. No. 5,943,238 (disclosing a barrel-type smart card programmingmechanism), the entire contents of each patent are incorporated hereinby reference. The card processing mechanism 14 may alternatively beconfigured to program a magnetic stripe on each card, or the cardprocessing mechanism 14 can perform both smart card programming andmagnetic stripe programming. In another embodiment, a separate magneticstripe programming mechanism (not illustrated) can be located betweenthe card processing mechanism 14 and the card feed mechanism 12 orbetween the card processing mechanism 14 and the card processingmechanism 16. In addition, the card processing mechanism 14 can belocated at other positions in the system 10 or is not used, in whichcase the card processing mechanism 14 is not between the card processingmechanism 16 and the card feed mechanism 12. The card processingmechanism 14, for example when configured as a smart card programmingmechanism, can also be located downstream of the card processingmechanism 16.

In the embodiment illustrated in FIG. 1, the card processing mechanism16 is shown as being downstream of the card processing mechanism 14. Inanother embodiment, the card processing mechanism 16 can be the firstprocessing mechanism downstream from the card feed mechanism 12 in whichcase the card processing mechanism 16 is not downstream of the cardprocessing mechanism 14. The card processing mechanism 16 is configuredto perform a processing operation on each card that is different thanthe card processing operation performed by the card processing mechanism14.

The embodiment illustrated in FIG. 1 also shows the card processingmechanism 18 as being disposed along the card processing path 22downstream of the card processing mechanism 16. However, other locationsof the card processing mechanism 18 in the system 10 are possible. Thecard processing mechanism 18 is configured to perform a processingoperation on each card that is different than the card processingoperations performed by the card processing mechanism 14 and by the cardprocessing mechanism 16. For example, the card processing mechanism 18can be configured to perform laser marking on each card using a laser,and/or apply a hologram overlay onto each card, and/or perform othercard processing operations. In one embodiment, the card processingmechanism 18 can have a card processing rate that is approximately equalto the first card rate. The card rate of the card processing mechanism18 refers to how fast (i.e. the rate) the card processing mechanism 18can perform its intended processing operation(s) on the cards.

Cards that have been processed are collected in the card output 20 thatis disposed along the card processing path 22 downstream of the cardprocessing mechanism 16. The processed cards can then be distributed totheir intended recipients, for example by attaching the cards to mailerforms and mailing to the intended recipients.

Many other card processing mechanisms can be used in addition to, or inplace of, the processing mechanisms illustrated in FIG. 1. For example,an indent mechanism that performs indenting on each card can be providedupstream of or downstream of the card processing mechanism 16. A qualityassurance mechanism that checks the quality of the processed cards canbe located between the card output 20 and the card processing mechanism18. Many other processing mechanisms, and combinations of processingmechanisms, can be utilized.

Referring now to FIGS. 2-4, for sake of convenience, the card processingmechanism 16 will be described as a card printing mechanism that isconfigured to perform printing, in particular drop-on-demand printingwith a UV curable ink. Suitable drop-on-demand printing mechanisms thatcould be utilized are sold under the tradename PERSOMASTER by AtlanticZeiser GmbH of Emmingen, Germany. FIGS. 2-4 illustrate a number ofdifferent cards 30 at different locations upstream of, downstream of,and within the mechanism 16. Each card 30 is numbered to help describedan example sequencing of cards. In addition, the letter “A” on a card 30indicates one side of the card 30, while the letter “B” indicates theopposite side of the card 30.

The mechanism 16 includes the at least one print station 26 on theprimary card travel path 24 that performs a printing operation onsurface A or B of each card 30 on the primary card travel path 24. Theprint station 26 can include a plurality of print heads 27 (shown inFIG. 5), some of which print a different color. Optionally, at least oneof the print heads 27 can apply a spray coating onto the card surface Aor B. In the case of drop-on-demand printing with a UV curable ink, anoptional surface treatment station 32 can be located on the primary cardtravel path 24 upstream of the print station 26. The optional surfacetreatment station 32, if used, is configured to treat the surface A or Bof each card 30 in order to lower the surface tension of the cardsurface so that the UV ink stays in place better when applied to thecard surface. In addition, a UV curing station 34 can be located on theprimary card travel path 24 downstream of the print station 26. The UVcuring station 34 is configured to apply UV light to the card surface inorder to cure the applied UV ink.

The return card travel path 28 intersects the primary card travel path24 both downstream of and upstream of the print station 26. The returncard travel path 28 is configured to divert or recirculate a card thathas been fed through the print station 26 from the primary card travelpath 24 and return the card back to the primary card travel path 24 at alocation upstream of the print station 26 so that the card can again befed through the print station 26. In addition, in some embodiments, asthe card is being recirculated along the return card travel path 28, thecard can be flipped 180 degrees so that the surface A or B that waspreviously printed on is now facing downward and the non-printed surfaceA or B is facing upward ready to be printed on.

The return card travel path 28 can have any configuration and locationthat is suitable for recirculating the cards upstream of the printstation 26 so they can fed through the print station 26 a second time,or even more than two times. The card return travel path 28 can have anygeneral shape as long as it functions to efficiently return cards to theprimary card travel path 24 upstream of the print station for a secondpass through the print station 26. In some embodiments, the return cardtravel path 28 can be on substantially the same plane as the primarycard path 24. Alternatively, the return card travel path 28 can belocated on a plane that is above or below the plane of the primary cardtravel path 24. In addition, the return card travel path 28 can besubstantially linear or it can be curved. In addition, any mechanism(s)for selectively recirculating the cards along the return card travelpath 28 and optionally flipping the cards 180 degrees can be used.

For example, in the embodiment illustrated in FIGS. 2-4, the card travelpath 28 can include a first portion 28 a that is substantiallyperpendicular to the primary card travel path 24, a horizontal portion28 b that is substantially parallel to the primary card travel path 24,and a second portion 28 c that is substantially perpendicular to theprimary card travel path 24. The mechanism 16 can include a firstmechanism 36 that can transport a card along the first portion 28 abetween the primary card travel path 24 and the horizontal portion 28 bso as to bring a card from the travel path 24 to the horizontal portion28 b of the travel path 28. A card flipper 38 can be provided along thehorizontal portion 28 b of the travel path 28 which flips a card 180degrees. This is evident from FIGS. 2-3 where card (6) is about to enterthe card flipper 38 with side A facing up in FIG. 2, and in FIG. 3 card(6) enters the card flipper 38 which flips the card (6) so that its sideB is now facing up. A second mechanism 40 is also provided that cantransport a card along the second portion 28 c between the primary cardtravel path 24 and the horizontal portion 28 b of the return card travelpath 28 so as to bring a card from the horizontal portion 28 b to thetravel path 24.

The mechanisms 36, 40 can have any configuration that can suitablytransport the cards between the primary card travel path 24 and theportion 28 a of the return card travel path 28. For example, asdiscussed further below in FIG. 5, the mechanisms 36, 40 can be rotationmechanisms that rotate each card from the primary card travel path 24 tothe portion 28 a of the return card travel path 28 (in the case of themechanism 36), and from the portion 28 a of the return card travel path28 back to the primary card travel path 24 (in the case of the mechanism40).

In other embodiments, the mechanisms 36, 40 can be elevator mechanismsthat transport the cards between the card travel paths. An example of acard elevator mechanism is disclosed in U.S. Pat. No. 6,105,493 theentire contents of which are incorporated herein by reference. In otherembodiments, a sequence of card flippers can be used to transport cardsbetween the card travel paths. Examples of card flippers are disclosedin U.S. Published Application No. 2013/0220984 and U.S. Pat. No.7,398,972 the entire contents of each are incorporated herein byreference.

Referring to FIG. 2, a sequence of cards 30 as they progress through themechanism 16 is illustrated at an arbitrary moment in time. This examplewill described as using the optional surface treatment station 32. Ifthe surface treatment station 32 is not used, a similar card sequencingcan occur but with one less card within the mechanism 16. Card (1) isshown as output from the mechanism 16 with side B facing upward. Card(7) is shown in position at the mechanism 36 with side A facing up readyto be transported to the portion 28 b of the card travel path 28. Card(6) is shown after having been transported to the portion 28 b of thetravel path 28, with side A facing up and ready to enter the flipper 38.Card (5) is shown in the flipper 38 and being flipped from side A toside B so that side B is now facing up. Card (4) is shown with card sideB facing up and ready to be brought by the mechanism 40 back to theprimary card travel path 24. Card (9) is shown with card side A facingup and having just entered the mechanism 16. Card (3) is shown in thesurface treatment station 32 with card side B facing up after havingbeen recirculated back to the travel path 24 so that side B can betreated prior to printing. Card (8) is shown in the print station 26with side A facing upward for printing on side A by the print station26. Card (2) is shown in the UV curing station 34 with side B facing upafter having been printed on, with the UV curable ink being UV cured inthe station 34. Card (10) is shown with side A facing upward and readyto enter the mechanism 16. Card (11) is shown with side A facing upwardand ready to take the position of card (10) once card (10) enters themechanism 16.

FIG. 3 shows the cards of FIG. 2 advanced one step in an example of onepossible sequencing of the cards in FIG. 2. Card (1) has not advancedand is shown in the same position output from the mechanism 16 with sideB facing upward. Card (7) with side A facing upward has been transportedby the mechanism 36 to the portion 28 b of the card travel path 28. Card(6) has been advanced along the card travel path portion 28 b into theflipper 38 and flipped from side A to side B so that side B now facesupward. Card (5) with side B facing upward has been advanced from theflipper 38 into the mechanism 40 ready to be transported back to theprimary card travel path 24. Card (4) with side B facing upward has beentransported by the mechanism 40 back to the primary card travel path 24.Card (9) with side A facing upward has been advanced into the surfacetreatment station 32 so that side A can be treated prior to printing.Card (3) with side B facing upward has been advanced into the printstation 26 for printing on side B. Card (8) with side A facing upwardhas been advanced into the UV curing station 34 after having beenprinted on, with the UV curable ink being UV cured in the station 34.Card (2) with side B facing upward has been advanced to the elevatormechanism 36 and the position formerly occupied by card (7).

FIG. 4 shows the cards of FIG. 3 advanced another step in an example ofone possible sequencing of the cards from FIG. 3. In this example, card(1) is advanced and card (2) is advanced from the mechanism 16 into theposition formerly occupied by card (1). Cards (7), (6) and (5) remain inposition. Card (8) is advanced from the UV curing station 34 into theposition formerly occupied by card (2). Card (3) is advanced into the UVcuring station 34. Card (9) is advanced into the print station 26 forprinting on side A. Card (4) is advanced into the surface treatmentstation 32 so that side B can be treated prior to printing. Card (10) isadvanced into the mechanism 16 into the position formerly occupied bycard (4) with side A facing upward. In addition, card (11) is advancedinto the position formerly occupied by card (10) and card (12) isadvanced into the position formerly occupied by card (11).

Once a card reaches the mechanism 36, if no further printing is requiredon the card, the card can be advanced through the mechanism 36 and outof the mechanism 16. At the same time, if a card is advanced out of themechanism 16, a new card can be transported into the mechanism 16 viathe mechanism 40 to begin the process of printing on a surface of thenew card. After a surface of the new card is printed, it can berecirculated back upstream of the print station 26 along the return cardtravel path 28 and flipped so that the other side of the new card facesupward, so that printing can occur on the other side of the new card.

If printing on both sides A and B of the card is not required, the cardcan be passed a single time through the print station 26 and then outputfrom the mechanism 16 without recirculating the card through the returncard travel path 28.

A method of processing cards in the card processing system 10 thatresults from the example system 10 and the example sequencingillustrated in FIGS. 2-4 includes printing on a first side (such as sideA) of a first card, for example card 8, using the print station 26. SeeFIG. 2. Thereafter, a second side (such as side B) of a second card, forexample card 3, is printed on using the print station 26. See FIG. 3.The second card, for example card 3, includes printing on a first side(such as side A) thereof that was previously applied to the first sidethereof using the print station 26. In other words, the second card, forexample card 3, was previously transported through the print station 26which printed on side A, with the second card, for example card 3,ultimately being recirculated back upstream of the print station andultimately fed back through the print station 26 to print on side B asillustrated in FIG. 3. In addition, after printing on the second side ofthe second card, for example card 3, the second side (such as side B) ofthe first card, for example card 8, is printed on in the print station26 as a result of the first card, such as card 8, ultimately beingrecirculated back upstream of the print station 26 and ultimately fedback through the print station 26 to print on side B using whichevercard sequencing is being implemented.

As is apparent from FIGS. 2-4, after printing on the first side of thefirst card, for example card 8, the side A or the side B of at least oneadditional card is printed on before printing occurs on the second sideof the first card, for example card 8. The printing on the additionalcard(s) occurs as the first card, for example card 8, is beingrecirculated back for printing on the second side thereof in the printstation 26. One additional card, two additional cards, three additionalcards, four additional cards, five additional cards, or more than fiveadditional cards, can be printed on as the first card, for example card8, is being recirculated back for printing on the second side thereof.

With drop-on-demand printing, it is preferable that the card beingprinted on in the print station 26 is oriented such that the card isoriented substantially flat or horizontal relative to the ground.However, in some card processing systems, cards may be transported alongthe card processing path 22 in a second orientation where the cards areoriented substantially vertically relative to the ground. Therefore, insuch an embodiment, upon reaching the mechanism 16, the cards need to bereoriented by rotating the cards 90 degrees, for example from a verticalorientation to a horizontal orientation, and upon exiting the mechanism16, the cards may need to be reoriented by rotating the cards 90degrees, for example from the horizontal orientation back to thevertical orientation.

FIG. 5 shows a portion of an embodiment of the mechanism 16 that isconfigured to reorient the cards 90 degrees at both the entrance and theexit of the mechanism 16. In this example, cards enter the mechanism 16in a vertical orientation. The mechanism 16 in FIG. 5 also has theprimary card travel path 24 and the portion 28 b of the return cardtravel path 28 is located next to and in the same plane as the primarycard travel path 24.

The cards can initially enter the mechanism 16 into an optional inputroller mechanism 50. The mechanism 50 can rotate about a vertical axisA-A. The mechanism 50 is useful for, if necessary, flipping the cardsabout the axis A-A so that if side A of a card is facing forward uponentry into the mechanism 16, the mechanism 50 can rotate the card sothat side B faces forward. If flipping of a card is not required, thecard can simply pass through the mechanism 50 without being flippedabout the axis A-A.

Each vertically oriented card is then fed into a first rotationmechanism 52. The rotation mechanism 52 is configured to receive eachcard, and then rotate in either direction about an axis that issubstantially parallel to the primary card travel path 24 to rotate thecard from its vertical orientation to a horizontal orientation that isaligned with the primary card travel path 24. The now horizontal cardcan then be transported from the mechanism 52 and onto the primary cardtravel path 24. The mechanism 52 can rotate 90 degrees in eitherdirection to bring the now horizontal card into alignment with theprimary card travel path 24. The mechanism 52 is also configured toreceive a card from the portion 28 b of the return card travel path 28and rotate 180 degrees along with the card about the axis that issubstantially parallel to the primary card travel path 24 to bring thecard back to the primary card travel path 24.

The now horizontal card is then transported past the print head(s) 27 ofthe print station 26 for printing on whichever surface is facingupwardly toward the print head(s) 27. Once printing is complete, thecard is fed into the UV curing station 34. After curing, the card is fedinto a second rotation mechanism 54 near the output of the mechanism 16.The rotation mechanism 54 is configured to receive each card, and thenrotate in either direction about an axis that is substantially parallelto the primary card travel path 24 to transport the horizontallyoriented card from the primary card travel path 24 to the portion 28 bof the return card travel path 28. In one embodiment, the rotationmechanism 54 rotates 180 degrees to transport the card from the primarycard travel path 24 to the portion 28 b of the return card travel path28 with the card still in its horizontal orientation. The card can thenbe transported along the portion 28 b of the card travel path 28 to theflipper 38 which can flip the card (if necessary) so that theappropriate side faces upward. The card is then transported into thefirst rotation mechanism 52 which rotates to transport the can back tothe primary card travel path 24.

An optional output roller mechanism 56 can be provided adjacent to theoutput of the mechanism 16. The mechanism 56 is similar in constructionand operation to the mechanism 50 in that the mechanism 56 can rotateabout a vertical axis A-A. The mechanism 56 is useful for, if necessary,flipping the cards about the axis A-A so that if side A of a card isfacing forward as it is about the exit the mechanism 16, the mechanism56 can rotate the card so that side B faces forward. If flipping of acard is not required, the card can simply pass through the mechanism 56without being flipped about the axis A-A.

The techniques described herein can be used with printing other thandrop-on-demand printing. For example, in the case of thermal dyediffusion printing, if printing is required on both sides A and B of thecard, the card can be recirculated back to the thermal dye diffusionprinthead. In the case of thermal dye diffusion printing, the stations32, 34 in FIGS. 2-4 would not be required, and reorienting the cardsfrom vertical to horizontal and from horizontal back to vertical wouldnot be required thereby eliminating the need for the rotation mechanisms52, 54.

The cards can be transported along the primary card travel path 24 andthe portion 28 b of the return card travel path 28, as well as along thecard processing path 22 through the mechanisms 14, 18 using any cardtransport mechanisms that are well understood by people of ordinaryskill in the art. For example, the cards can be transported usingrollers, belts, and combinations thereof.

The mechanisms 12, 14 and 18 have been described as having card ratesapproximately equal to one another (for example each up to about 300cards per hour), and the mechanism 16 has been described as having acard rate (for example up to about 6000 cards per hour or even greater)that is greater than the card rates of the mechanisms 12, 14, 18.However, the mechanisms 12, 14, 16 and 18 can have card rates that areapproximately equal to one another.

The examples disclosed in this application are to be considered in allrespects as illustrative and not limitative. The scope of the inventionis indicated by the appended claims rather than by the foregoingdescription; and all changes which come within the meaning and range ofequivalency of the claims are intended to be embraced therein.

The invention claimed is:
 1. A card printing mechanism comprising: acard input end having a card input through which plastic cards can beinput into the card printing mechanism; a primary card travel pathextending from the card input along which the plastic cards can travelin a first direction after being input through the card input; a printstation on the primary card travel path downstream from the card inputthat performs a printing operation on surfaces of the plastic cards onthe primary card travel path, the print station includes at least oneprint head; a return card travel path, separate from the primary cardtravel path, along which the plastic cards can travel to be returnedback to the primary card travel path at a position upstream of the printstation, the return card travel path includes a portion that issubstantially parallel to a portion of the primary card travel pathhaving the print station, and the plastic cards travel in a seconddirection opposite the first direction when on the portion that issubstantially parallel to the portion of the primary card travel pathhaving the print station; a card output end having a card output throughwhich plastic cards can be output from the card printing mechanism; andthe portion of the return card travel path that is substantiallyparallel to the portion of the primary card travel path having the printstation is located on a same plane as the portion of the primary cardtravel path having the print station.
 2. The card printing mechanism ofclaim 1, wherein the print station comprises a drop-on-demand printstation and the at least one print head prints using UV curable ink; andfurther comprising a UV curing station located on the primary cardtravel path downstream of the drop-on-demand print station.
 3. The cardprinting mechanism of claim 1, further comprising a card surfacetreatment station on the primary card travel path between the printstation and the card input.
 4. The card printing mechanism of claim 1,further comprising a card flipper that is configured to flip a plasticcard after the plastic card has been printed in the print station. 5.The card printing mechanism of claim 1, where the print stationcomprises a plurality of print heads.
 6. The card printing mechanism ofclaim 1, wherein the card printing mechanism is configured so that afirst plastic card, a second plastic card, and a third plastic card arelocated in sequential order on the primary card travel path; each of thefirst plastic card, the second plastic card and the third plastic cardshas a first side and a second side opposite the first side; the firstplastic card and the third plastic card are oriented with the firstsides thereof facing upward, and the second plastic card is positionedbetween the first plastic card and the third plastic card and the secondplastic card is oriented with the second side thereof facing upward. 7.A card printing mechanism comprising: a card input through which plasticcards can be input into the card printing mechanism; a primary cardtravel path extending from the card input along which the plastic cardscan travel in a first direction after being input through the cardinput; a print station on the primary card travel path downstream fromthe card input that performs a printing operation on surfaces of theplastic cards on the primary card travel path, the print stationincludes at least one print head; a return card travel path, separatefrom the primary card travel path, along which the plastic cards cantravel to be returned back to the primary card travel path at a positionupstream of the print station after being printed on in the printstation; a card output through which plastic cards can be output fromthe card printing mechanism; wherein the card printing mechanism isconfigured such that the plastic cards on the primary card travel pathare arranged in an alternating sequence where a first one of the plasticcards has a first orientation with a first surface thereof facing upwardand a second surface thereof facing downward and a second one of theplastic cards in sequence following the first plastic card has a secondorientation with the first surface thereof facing downward and thesecond surface thereof facing upward.
 8. The card printing mechanism ofclaim 7, wherein the print station comprises a drop-on-demand printstation and the at least one print head prints using UV curable ink; andfurther comprising a UV curing station located on the primary cardtravel path downstream of the drop-on-demand print station.
 9. The cardprinting mechanism of claim 7, further comprising a card surfacetreatment station on the primary card travel path between the printstation and the card input.
 10. The card printing mechanism of claim 7,wherein the return card travel path includes a portion that issubstantially parallel to the primary card travel path, and the portionof the return card travel path is located on a same plane as the primarycard travel path.
 11. The card printing mechanism of claim 7, furthercomprising a card flipper that is configured to flip a plastic cardafter the plastic card has been printed in the print station.
 12. Thecard printing mechanism of claim 7, where the print station comprises aplurality of print heads.
 13. A card processing system, comprising: acard feed mechanism, a card printing mechanism, and a card processingpath extending from the card feed mechanism to the card printingmechanism; the card printing mechanism includes: a card input incommunication with the card processing path and through which plasticcards from the card feed mechanism can be input into the card printingmechanism; a primary card travel path extending from the card inputalong which the plastic cards can travel in a first direction afterbeing input through the card input; a print station on the primary cardtravel path downstream from the card input that performs a printingoperation on surfaces of the plastic cards on the primary card travelpath, the print station includes at least one print head; a return cardtravel path, separate from the primary card travel path, along which theplastic cards can travel to be returned back to the primary card travelpath at a position upstream of the print station after being printed onin the print station; a card output through which plastic cards can beoutput from the card printing mechanism; wherein the card processingsystem is configured such that each of the plastic cards fed from thecard feed mechanism reach the card input in a first orientation with afirst surface of each plastic card facing upward and a second surface ofeach plastic card facing downward; and the plastic cards on the primarycard travel path are arranged in an alternating sequence where a firstone of the plastic cards has the first orientation and a second one ofthe plastic cards in sequence following the first plastic card has asecond orientation with the first surface thereof facing downward andthe second surface thereof facing upward.
 14. The card processing systemof claim 13, wherein the print station comprises a drop-on-demand printstation and the at least one print head prints using UV curable ink; andfurther comprising a UV curing station located on the primary cardtravel path downstream of the drop-on-demand print station.
 15. The cardprocessing system of claim 13, further comprising a card surfacetreatment station on the primary card travel path between the printstation and the card input.
 16. The card processing system of claim 13,wherein the return card travel path includes a portion that issubstantially parallel to the primary card travel path and located on asame plane as the primary card travel path.
 17. The card processingsystem of claim 13, further comprising a card flipper that is configuredto flip a plastic card after the plastic card has been printed in theprint station.
 18. The card processing system of claim 13, furthercomprising a smart card programming mechanism disposed in the cardprocessing path between the card feed mechanism and the card printingmechanism, the smart card programming mechanism is configured to programa chip embedded in each of the plastic cards fed from the card feedmechanism onto the card processing path.